This project provides a comprehensive guide to the operation panel of a CNC EDM wire-cutting machine, helping students understand how to adjust, prepare, and operate the machine effectively. It covers program input, modification, and practical examples of machining parts to ensure a clear understanding of the entire process.
Project 1: Machine Operation Panel and Functional Application
The operation panel includes the control panel and the hand-controlled box panel, similar to fast wire EDM machines. However, since this is a single-direction wire-cutting machine, it does not have a storage tube or its corresponding panel. This simplifies the interface but requires more precise manual control during operations.
Project 2: Startup Procedure
The startup process involves the following steps:
- Turn on the main power switch.
- Press the start button on the control panel to activate the CNC system and the machine tool.
Project 3: Wire Installation
To install the wire, follow the threading path shown in Figure 1. The wire should pass through the compacting drum, drum, guide wheel, constant tension control wheel, upper guide, workpiece, and lower electrode before reaching the wire reel. Adjust the servo motor's constant tension control device to maintain proper tension for stable operation.
For slow wire EDM processes, the distance between the upper guide and the workpiece should be as close as possible (about 0.05–0.10 mm) to prevent excessive wire vibration, which can affect machining quality. After installation, verticality must be checked using the same method as with fast wire EDM machines.
Project 4: Workpiece Installation
Tools such as bridge fixtures, wire verticality inspection tools, rotary tables, and CNC rotary tables used in fast wire EDM can also be applied to slow wire EDM. Recently, universal clamping fixtures and alignment tools have been introduced, making workpiece alignment and clamping quick and accurate, as shown in Figure 2.
Project 5: Program Input
According to the machine’s manual, programs are generated by switching between different modules, either by entering them via the keyboard or calling pre-stored programs. Before running the actual program, simulate it to check for any errors and avoid potential issues. Press the ENT key to execute the program and begin machining.
Project 6: Program Operation
Use small and multiple cutting methods for better results. This approach helps reduce material deformation during cutting, improving both accuracy and surface finish. A small margin is left during roughing or semi-finishing to account for stress changes, allowing for a final finishing cut that delivers high-quality results.
Project 7: Part Inspection
After machining, remove the part and measure the relevant parameters to ensure it meets specifications.
Project 8: Shutdown Procedure
Follow these steps to shut down the machine safely:
- Move the workbench to the center position of each axis.
- Press the red emergency stop button.
- Turn off the main power switch.
- Disconnect all external connections.
This detailed guide ensures that students gain hands-on experience and a thorough understanding of operating a CNC EDM wire-cutting machine efficiently and safely.
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